Apparatus for the manufacture of ornamental paper



June 24, 1930. MAHLER El AL APPARATUS FOR THE MANUFACTURE O ORNAMENTAL PAPER Original Filed April 1, 1926 6 Sheets-Sheet l Invanfora- .EFZZSZ Mafia,

June 24, 1930. 4 MAHLER ET AL 1,767,252

APPARATUS FOR THE MANUFACTURE OF ORNAMENTAL PAPER Original Filed April 1, 1926 6 Sheets-Sheet 2 a Q u Q a Q n a a a o u q o a Q;

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June 24, 1930. E. MAHLER E AL APPARATUS FOR THE MANUFACTURE OF ORNAMENTAL PAPER Original Filed April 1. 1926 6 Sheets-Shem: 5

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June 24, 1930. E. MAHLER ET AL 1,767,252

APPARATUS FOR THE MANUFACTURE OF ORNAMENTAL PAPER Original Filed April 1, 1926 s Sheets-Shet 4 .1? rnst jl fgzk r? Charles Bright,

@wmw w June 24,1930. E. MAHLER ET AL 1,767,252

APPARATUS FOR THE] MANUFACTURE OF ORNAMENTAL PAPER Original Filed April 1, 1926 6 Sheets-Sheet 5 InvenZErs: fm'zs Mel/M67; Charles G .Bfiz 'ghfi,

6 Sheets-Sheet 6 E. MAHLER ET AL APPARATUS FOR THE MANUFACTURE OF ORNAMENTAL PAPER Original Filed April 1 1926 June 24, 1930.

Patented June 24, 1930 um'rso STATES PATENT OFFICE V ERNST MAHLER AND CHARLES BRIGHT, F NEENAH, WISCONSIN, ASSIGNORS TO PAPER PATENTS COMPANY, CONSIN.

OF NEENAH, WISCONSIN, A CORPORATION WIS- I APPARATUS FOR THE MANUFAfJTURE 0F OBNAMENTAL PAPER Application filed April 1, 1926, Serial No. 98,952, and in Canada October 9, 1925. Renewed Our invention relates to ornamental paper and also to the apparatus for the productlon of the same, and specifically to wall paper 1n which the desired effect is produced during and in theprocess of manufacture of the same without printing or other treatment thereof after the nianufacture of the paper is completed and to an apparatus for the production of such Wall paper. This application is a continuation in part of our application, Serial No. 54,004, filed September 2, 1925, covering the method or process of making said paper. The apparatus is claimed in the present application, while the article and process of making the same are claimed in our copending application Serial No. 106,139 filed May 1, 1926.

The principal object of our invention is to produce wall paper having the characteristics above set forth, and to provide an improved. eflicient and practical apparatus for the production thereof. 1

Wall paper embodying out invention and constituting the novel product thereof comprises a base, preferably with a rough surface texture such as the so-called oatmeal paper, that has embodied therein areas of similar or different colors, and comprises also an overlayer, preferably of blending stock, that is to a large extent incorporated with the base and which produces a cloud effect. The paper may also have a second coloring for producing the effect of an irregular surface. A further object of our invention is therefore to produce awall paper that. gives the effect of an irregular surface having color efi'ects overlaid by a cloud effect and in which the materials producing such effects are embodied in the paper during the manufacture and before the completion thereof, and to provide an apparatus for the production of such paper. A further object of our invention isto produce a wall paper in which the application of the above mentioned second coloring is so controlled as to produce a supplementaldesi and to provide an apparatus for the pro notion of such paper. A further obect of ourinvention is to produce a wall paper having certain of the characteristics above described in which the color a1 eas are January in the form of nebulous or cloud-like tints diminishing in strength toward their'edges and incorporated in the paper beneath the surface thereof and preferably underneath materials producing other effects rather than being in the form of mere surface spots or stains.

-The coloring of the wall paper base by means of areas of incorporated or. partially submerged tints of variegated colors as contrasted with mere surface printing or staining constitutes an important feature of our invention and said effect is modified and enhanced by the cloud effect of the overlayer of blending stock, by the second coloring that produces the effect of an irregular surface, and also in a measure by the use of pulp containing coarse particles for the production of the wall paper base. The embodiment ,within the paper during its manufacture of ited by mere surface coloring, particularly 7 i when the effect of an irregular surface is imparted by embodiment of the above mentioned second coloring.

In order that the overlayer of blending stock may be so incorporated with the base as to produce a desiredclouddike elfectand the impression or illusion of depth, the blending stock, in accordance with our invention, is applied to the base shortly after the stock that orms the base has passed the main slice that is associated with the supply of that stock. The effect "produced is obviously different from the effect that would be produced by applying the blending stock after the formation of thebase sheet is virtually completed and after'the mingling or incorporation of the blending stock with and below the surface of the base stock is impossible or possible to only a slight degree. A

Wall paper embodying our invention and made inaccordance therewith and by the use is to provide apparatus whereby the liquid coloring that is incorporated in nebulously defined areas of the base stock may be so controlled in its delivery to the stock as to produce the desired effect.

The second coloring is applied by a spray that projects the coloring against the incompleted paper or rather along the surface thereof in such mannerthat the uneven contour or natural irregularities of the unrolled and otherwise incompleted'paper determine the distribution of the color. The lights and shadows thus produced appear as such in the completed paper, and convey the illusion of a rough or uneven contour, although the paper is actually smooth and flat. Also in accordance with our invention such application of the second coloring maybe interrupted or prevented along certain lines in order to produce a further, and preferably regular, design by means of lines or areas free of the second coloring. The effect of an irregular surface is enhanced by the fact that the first applied tints are not only embodied in the paper but overlaid with the blending stock that produces the cloud effect so that the various materials applied to produce various effects cooperate to give a final non-uniform or haphazard but nevertheless sufliciently regular appearance that has variation of color, of nebulous outline partly submerged by a cloud-like effect and having the lllllSlOIl of a rough contour, the total effect being one of depth and free of definite outline and tiresome regularity.

In 'ap l g our invention to existing Fourdrin iei' rhachines, it was found that devices then available in the art for the purpose of applying liquidcolor in the form of drops were very unsatisfactory and enerally couldnot be depended upon to pro uce uniform results of the character-desired. Therefore, it became necessary to devise special color depositing apparatus, which apparatus also constitutes a rather important feature of the invention as a whole.

The apparatus which we prefer to use and which we have used successfully in practicing our invention, is disclosed in the accompanying drawings, wherein i- Fig. 1 is a side elevation of the organized apparatus.

Fig. 2 is a plan view of the same.

Fig. 3 is an elevation of the special devices for applying or depositing the liquid color.

Fig. 4 is an elevation of the apparatus for applying the final spray when such is desired. v

Fig. 5 is an enlargement, partly in section, of a portion of Figure l.

Fig. 6 is a section taken on the line 6-6 of Figure 3.

Fig. 7 is an enlargementef one of the spray heads shown in Figure 4.

Fig. 8 is a section taken on the line8-8 of Figure 7.

of Figure 7.

Fig. 10 is an enlargement of a portion of t Figure 7, the parts being shown in section.

Fig. 11 is a section taken on the line 11-11 of Figure 10, and

Fig. 12 is an enlarged fragmentary section taken transversely across the wire at the point of application of the marking roll.

The invention is illustrated as applied to aFourdrinier machine of the ordinary type which is equipped with the usual wire screen %0, breast roll 21 and any desired type of ow main stock supply from which the base sheet is formed. One or more slices may be used. In the present instance, two such slices 23 and 24 of the usual design are employed. The machine is equipped with the usual suction boxes 25, 26, and 27 which, however,.may be dispensed with in certain 'cases, depending upon the particular type of paper which is bein produced. Also in order to produce a finis ed paper of suflicient body and strength to withstand handling and facilitate application to the wall, it is preferableto duplex, that is to say, to combine the main or top sheet 28 made according to the invention with a @bottom web 29 formed of ordinary stock which serves merely as a support for the top sheet. Said duplexing idea, which is extremely old in the art, obviously constitutes.

art of our invention. order to apply the cloud forming blendin stock to the surface of the inchoate web be ore the formation thereof is completed,

.ci. e. while the base stock is still in a relative fluid condition, a special form of secondary flow box and stock distributing device is used. Said blending stock preferably comprisesa good grade of sulphite stock preferably of a heavier consistency than that of the base stock and flows by gravity from the blending stock head box 30. The blend flows from head box through a pipe 31 into the secondary flow box 32 which is equipped with suitable baflies 33 and 3 for the purpose of effecting proper distribution and quieting of the stock. The delivery side of the flow box 32 is reduced in height and equipped with a curved apron 35 WhlCll delivers the stock in a direction towards the breast roll 21 and deposits same upon or slice 36, the edge 37 of which is as close as possible to the surface of the wire and substantially tangential thereto so that the blending stock will be delivered to. the wire in a surface thereof.

It will be manifest that with the blend stock distributing devices as abovedescribed,

the blending stock will be evenly applied to direction substantially parallel with the a reversely curved apron the surface of the base, and since the flow apron 36 is located quite close to the main slice 24, the blending stock although deposited on the surface of the base sheet, willbe largely incorporated with the base, although the surface will be quite mountainous or lumpy.

Describing the special devices which are employed for depositing drops of liquid color onto the base sheet intermediate the 'main slice 24 and the blending apron 36, it will be observed that the said color flows from four independent color supply sources so that four different colors may be employed, if desired. Hence the apparatus can be used to produce a paper having a so-called tiffany efl'ect. Preferably, as a matter of convenience, the nozzles or spouts 38 leading from all of the color supply sources are located in the same line extending transversely across the machine. Said nozzles are supported in an apertured angle iron cross member 39 and receive their supply of liquid color from flexible tubes 40, the upper ends of which fit over the depending spouts or small funnels 41 suitably positioned to receive the droppings from the individual color supply nozzles as at 42.

The different colors flow from four independent supply sources and as all of said sources are similarl equipped, only one of same need be descri ed. Referring particularly to Fig. 3, 43 indicates a sump tank for the liquid color and 44 is a small constantly driven pump, by means of which a constant supply of color from the sump tank .43 is forced up through a supply pipe 45 and into the color head box 46. A level of liquid in the head box 46 is maintained constant by means of a relatively large overflow pipe 47 which discharges downwardly into the sump tank 43.

By means of a pipe 48, the liquid color from the head box 46 is conducted to the remote end 49 of a horizontally disposed manifold pipe 50 which extends transversely across the machine and directly over one of the rows of the drop guiding funnels 41 Sai d manifold pipe 50 is equipped with a similar number of drip nozzles 42 properly spaced to register with said funnels 41.

As is shown best in Fig. 6, each of said drip nozzles 42 comprises an axially vertical nipple element or bleed tube 51 threaded to fit a correspondingly threaded aperture in the bottom wall of the manifold pipe 50. By means of a hexagon head 52 onthe nipple 51, the latter may be adjusted in a vertical direction so that all of the nipples may be positioned in the same horizontal plane. The

. actual opening in the bleed duct or opening 51 which extends vertically and axially through the same is comparatively small in diameter and care should be taken to see that the said aperture or conduit is maintained free and unobstructed throughout its length, Also the lower end of the nipple 51 as shown at.42, should preferably bemade in the form of a downwardly pointing cone.

A special and, it is believed, an entirely novel arrangement is provided for the purpose of maintaining a constant pressure or head at the nipples, so as to insure a sufliciently positive and sufficiently uniform deposit of color on the sheet. Heretofore, this has been a diflicult problem. On the one hand, it has been found impossible or not practical to use an extremely fine aperture in the drip nozzles because if made too small the apertures will clog and refuse to function. On'the other hand, if the apertures were made too large, the supply of color would be altogether too voluminous to give the required effect unless the hydrostatic pressure at the nozzle was very, very small. To those skilled in the art, it will be obvious that the problem of maintaining a hy drostatic pressure limited in amount to an inch or so of water column while maintaining said head constant within a few percent, is not a simple one. It has, however, been successfully solved by the use of the following described apparatus. 4 i

Referring to Fig. 3, it will be observed that to the end 53 of manifold pipe 50, there is connected a dischargepipe or a turn flow pipe 54 connecting with the upper end of a barometric'pipe 55, the lower end of which discharges into a funnel-like box 56 equipped with a suitable strainer 57 and discharging into the sump tank 43. The capacity of the barometric pipe 55 is such that same will always run full of liquid and deliver a solid stream at its lower end. Its effect is obviously to create a suction at the end 53 of the manifold pipe .50 and such sucking action will be of a uniform amount provided that the flow of liquid through pipes 54 and 55 is substantially constant so as to eliminate head losses, due to friction.

In practice, when regulatingor initially setting the head for the drip nipples, the regulating valve 56 in the supply line 48 is adjusted to control the rate of flow of color into the manifold 50. When said valve 56 is fully open, the manifold is subjected to substantially full pressure corresponding with the elevation of liquid in the head box 46 and under this .condition the barometric suction, being reduced somewhat by friction in pipes 54 and 55, is substantially less than the pressure due to the elevation of liquid in the head box 46 so that the liquid in the manifold 50 will be at a pressure substantially above'that of the atmosphere.- Hence, the color flows out of the manifold through the nipples 51 at a maximum rate. If less than a maximum fiow'out of the nozzles is required, the valve 56 is partially closed so as to reduce the flow and pressure of the liquid through pipe 48 and in'manifold' 50, which will incidentally reduce the flow of liquid through pipes 54 and 55. 1 Asa result there will be a reduced loss due-to friction of liquid ing devices'through and 79 on bracket 74.

flowing through pipes 54 and 55 and the sucking action at point 53 will be correspondingly greater, thus further reducing the pres sure in manifold 50. By suitably regulating the flow of liquid by valve 56, the pressure fluid in the manifold 50 may be correspondingly regulated and such regulation can obviously be effected with extreme accuracy so as to secure any desired rate of flow out of the nipples 51. I

In order to produce on such paper the effect of high lights and shadows so as to create the illusion of an irregular as distinguished from a plain surface, the surface of the paper may be subjected to a spraying op-' eratlon, such for example as is disclosed in the United States patent to Mahler No.

1,329,130, issued January 27, 1920. Said spraying operation is effected by means of the following improved apparatus.

Referring to Fig. 4, 57 is a sump tank for containing a supply ofliquid color which, by means of a suitable constantly driven pump-58 is circulated through a head box P 59. Said head box 59 supplies the spraya suitable supply line 60. Said spray heads, as shown best in Fig. 4, are disposed in a series extending across the web and preferably at a slight angle as shown in Fig. 2. The supporting devices for such spray heads preferably comprise a pair of columns 61 and 62 disposed respectively on opposite sides of the machine and connected by a transverse horizontally disposed tubular bar 63. The tops of said columns 61 and 62 are also connected by a similar transverse bar 64 which supports the liquid color manifold 65 and the air pressure manifold 66. The liquid supply manifold 65 is connected at one end with the li uid supply line'60 and the air supply mani old 66 is supplied with air under pressure through a suitable hose 67. The spray heads which are supported on bar 63, are adjustable thereon and to permit such adjustment the individual spray heads are connected to the manifolds 65 and 66 by individual flexible tubes or hoses as 67 and 68.

For each spray head there is rovided a split clamp 69 slidable along an rotatable around the bar 63 and capable of being locked thereon in an position by means of a suitable wing screw 0. On the side of the clamp 69 opposite to the split 71 there is facing boss 72 to which, by suitable cap screws 73 there is bolted a main bracket 74. Said bracket 74 is fitted with a slideway 75 in which there is slidabl mounted a slide block 76. Said slide b ock 76 is drilled longitudinally and tapped to accommodate a screw 7 7, the ends of which are rotatably supported in lugs 78 One end of the screw 77 is made with an enlarged head 80 suitably knurled to permit manual adjustment of the said screwr By means of the screw 77 annular worm gear the slide box 76 can be raised or lowered largement 81 and is made in two pieces asshown best in Fig. 7, the two parts 82 and 83 being detachably secured together on one side by a pin 84 and on the other side by means of a swinging lock bolt 85. Said parts are separable for the purpose of 86 fitting within a circular recess 87 bored out in said enlargement or member 81 and undercut as shown in order to retain said gear 86 securely in said enlargement. or housing81. The housingportion 82 is equipped with a worm screw 88 having a knurled head 89, said screw 88 meshing with the worm gear 86 so that the worm 86 may be rotated within said housing 81.

The gear 86 is constructed with a laterally projecting tension housing as best shown in Figs. 8 and 9. Said housing 91 is made in-two parts 92 and 93 normally secured together by a in 94 on one side and a swing bolt 95 on the other side. Within said housing 91 there is rotatably mounted a worm gear 96 which may be rotated by aknurled head screw 97 which meshes with the teeth of the worm gear 96.

The worm gear 96 is drilled vertically to accommodate the air pipe 98 and color supply pipe 99, vertical movement of said. pipes in the gear block 96 being prevented by clamp members 100 and 101 in cooperation with a clamping screw 102. The upper ends of the supply pipes 98 and 99 are connected to the hoses 68 and 67 by suitable unions 103 and 104 and the lower ends of the said ipes 98 and 99 are connected to the spray head proper 'by means of unions 105 and 106.

Describing the spray head proper, 107 represents a yoke casting which steadies and connects the ends of the air supply nipple 108 and liquid supply nipple 109, which nipples are respectively threaded into housings 110 and 111. The housing 111 is laterally tapped to accommodate the enlarged andthreaded end 112 of the small diameter tube 113 which extends through the housin 110 and almost to the end of the outlet ori ce or nozzle 114.

Said nozzle 114 is tapped to fit a correspondingly threaded nose 115 on the end of housing 110, said nose 115, as indicated in Figure 11, being formed with a series of apertures 116 for conducting air into the tip of the hollow nozzle 114.

bracket 90 having a circular ex admitting an The rear end of .the'housing 110 is made with a neck portion 117 which is threaded to accommodate the 'stufling box 118. Said stufiing box 118 is equipped with a suitable flexible packing 119 which surrounds the tube or stem 113 and prevents leakage of liquid color from the spray head.

Bymeans of the various adjustments heretofore described, the position of the spray nozzle and the angle at which the spray is directed against the surface of the paper may be adjusted positively and with great precision which is found to be of the greatest importance in spraying devices of this character. In order to secure the desired uniform effect and to prevent shading or banding, the spray nozzles should be individually adjustable otherwise lack of uniformity across the width of the paper will inevitably result.

For the purpose of obtaining relatively simple effects by means of the spraying devices, the web may be subjected to such spray in the condition as it comes from the color dropping and blending devices without recourse to any intermediate treatment, it being understood that the side shake is dispensed with as is described in said Mahler patent. As distinguished from the effect produced by the Mahler patent supra, the lumps or mountains caused by the application of the blending stock result in a pronounced accentuation of the natural roughness of the paper. Hence, the illusion of a .rough contour produced by the spray is very marked, the surface of the paper having a mountainous as distinguished from a merely rough appearance.

However, a different effect or an eli'ect in the form of a pattern design may be impressed upon the paper by suitably conforming the surface of the web before it passes into the zone of the spraying devices. As an example of such treatment, there is shown in Figs. 1, 2, and 12, a grooving roll 120 which is applied to the web in the region of the suction boxes, and in the same position that would be occupied by the dandy roll in making ordinary paper. In the present instance, such roll is shown as being constructed in the form of a cylindrical wire cage, the wires extending circumferentially around the periphery of the roll as shown best in Fig. 12. It is not ordinarily necessary to apply any driving power to the forming roll which may be supported merely in suitable journals on opposite sides of the machine.

By means of a forming roll such as just described, the surface of the moist web is impressed with a series of lon itudinally extending grooves, the edges of which receive the impact of the spray so that the pattern of the roll is permanently shown upon the surface of the finished paper by the spray color markings. The paper retains the said markings even though it may be subsequently pressed out fiat and dried in the usual way.

\Ve claim as our invention:

1. In apparatus for making ornamental paper, the combination with the usual traveling screen, main flow box, and slice, of a secondary flow box for blending stock beyond said slice, guide aprons for delivering the blending stock from said secondary fiow box onto the base layer coming from the main flow box in the direction of travel of said base layer and while the latter is still in a fluid condition, means for depositing drops of liquid color onto the base layer between said of a manifold extending horizontally across i the bed of the machine, drip nozzles on the lower side.of said manifold in continuous communication with the interior of the latter, tubes having funnels on their upper ends underlying said drip nozzles, and means for creating a continuous flow of liquid color under a substantially constant pressure through said manifold.

4. In a liquid color depositing apparatus for paper making machines, the combination of a manifold extending horizontally across the bed of the machine, drip nozzles on the lower side of. said manifold, tubes having funnels on their upper ends underlying said drip nozzles, a color head box, a flow pipe from said head box to one end of'said manifold, a return line from the other end of said manifold to said head box, a pump in said return line, and means for maintaining a constant level of liquid in said head box;

5. In a liquid color depositing apparatus for paper making machines, the combination of a manifold extending horizontally across the bed of the machine, drip nozzles on the lower side of said manifold, tubes having funnels on their upper ends underlying said drip nozzles, a sump tank for liquid color, a color head box above said sump tank, a flow pipe from said head box to one end of said manifold, a return flow pipe from the other end of said manifold to said sump tank, means for pumping liquid color from said sump tank to said head box, and an overflow pipe for maintaining a constant liquid level in said head box.

6. In a liquid color depositing apparatus for paper making machines, the combination of a manifold extending horizontally across the bed of the machine, drip nozzles on the lower side of said manifold, tubes having funnels on their upper ends underlying said drip nozzles, a sump tank for liquid color, a color head box above said sump tank, a flow pipe from said head boxto one end of said ing screen,

manifold, a valve in said flow fiiipe regulating the rate of flow, a return ow pipe, including a barometric column, from the other end of said manifold to said sump tank, a continuously operating pump delivering liquid color from said sump ,tank to said head box, and an ovei'flow pipe from said head box to said sump tank operative to maintain a constant level of liquid in said head box.

7. In apparatus for making ornamental paper, the combination with the usual travelmain flow box and slice, of a secondary flow box for a blending stock beyond said slice, means for guiding the blending stock from said secondary flow box base layer coming from the main flow box, and means for depositing drops of liquid color on to the base layer between said slice and said guiding means.

8. In a liquid color depositing apparatus for paper making machines, the combination of a reservoir for liquid color, means for maintaining the liquid level in said reservoir at a constant height, an apertured manifold, a gravity flow conduit connecting said reservoir with one end of said manifold, and a barometric conduit discharging liquid color from said manifold.

9. In a liquid color depositing apparatus for paper making machines, the combination of a reservoir for liquid color, means for maintaining the liquid level in said reservoir at a constant height, an apertured manifold,

.a gravity flow pipe connecting said reservoir with one end of said manifold, a barometric pipe connected to the other end of said manifold and discharging liquid color therefrom, and a regulating valve in one of said pipes.

10. In a li uid color depositing apparatus for paper ma of a reservoir for liquid color, means for maintaining the liquid level in said reservoir at a constant height, a manifold having a plurality of spaced apertures in its lower side, a gravity flow pipe connecting said reservoir with one end of said manifold, a barometric pipe connected to the other end of said maniold, and a regulating valve in said gravity flow pipe.

on to the ing machines, the combination pipes connecting said flexible tubes with spray head, and means for clamping said pipes to said auxiliary bracket.

12. In apparatus for making ornamental paper, the combination with a traveling Fourdrinier wire. to support a paper web while forming, of means ,for sprayin liquid color on the upper surface of said we said spraying means comprising a frame extendin above said wire, liquid color and compresse air "manifolds mounted on the upper endof said frame, flexible tubes depending from said manifolds, a main bracket mounted on a member of said frame, a slide block vertically adjustable on said main bracket, an auxiliary bracket mounted on said slide block, means for adjusting said auxiliary bracket around a horizontal axis, a horizontally disposed spray head, liquid color and compressed air-pipes connecting said flexible tubes with said sprayhead, and a rotatable supporting member for said pipes mounted in said auxiliary bracket by means permitting its adjustment around a vertical axis.

ERNST MAHLER.

CHARLES G. BRIGHT.

11. In apparatus for making ornamental paper, the combination with a traveling Fourdrinier wire to support a paper webwhile forming, of means for spraying color on the upper surface of said web, said spra g means comprising a frame extending a ove said wire, liquid color and compressed air manifolds mounted on the upper end of said frame, flexible tubes depending from said manifolds, a main bracket mounted on a memslide block vertically ad racket mounted on saidslide block, means for adjusting said auxiliary bracket around a horizontal axis, a horizontally disposed spray head, liquid color and compressed air.

Lustable on said main bracket, an auxiliary 

